Battery parts and associated systems and methods

ABSTRACT

Battery parts, such as battery terminals, and associated systems and methods for making same. In one embodiment, a battery part has a sealing region or sealing bead located on a lateral face of an acid ring for increasing resistance to leakage therepast as the battery container shrinks. Another embodiment includes a forming assembly for use with, for example, a battery part having a bifurcated acid ring with spaced apart lips. The forming assembly can include movable forming members that can be driven together to peen, crimp, flare or otherwise form the lips on the bifurcated acid ring.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a Continuation of U.S. patent application Ser. No.14/225,239, filed Mar. 25, 2014, now issued as U.S. Pat. No. ______,which is a Divisional of U.S. patent application Ser. No. 12/533,413,filed Jul. 31, 2009, now issued as U.S. Pat. No. 8,701,743, which is aContinuation-In-Part of U.S. patent application Ser. No. 11/011,362,filed Dec. 13, 2004 and entitled “BATTERY PART,” which claims priorityto U.S. Provisional Patent Application No. 60/533,924, filed Jan. 2,2004 and entitled “BATTERY PART AND METHOD OF MAKING,” and which is alsoa Continuation-In-Part of U.S. patent application Ser. No. 10/804,401,now U.S. Pat. No. 7,338,539, filed Mar. 18, 2004 and entitled “DIE CASTBATTERY TERMINAL AND A METHOD OF MAKING,” which also claims priority toU.S. Provisional Patent Application No. 60/533,924, filed Jan. 2, 2004and entitled “BATTERY PART AND METHOD OF MAKING,” each of the foregoingpatents and patent applications is incorporated herein in its entiretyby reference.

TECHNICAL FIELD

This invention relates generally to battery parts and, morespecifically, to battery parts and a methods and systems for flaring orotherwise forming an acid ring on the battery part.

BACKGROUND

Battery parts such as battery terminals, which are typically cold formedor die cast, are normally secured to a container with a portion of thebattery terminal located inside the container and a further portionlocated outside the container. The battery containers, which aretypically plastic such as polyethylene, are molded around a set of acidrings that are located on the portion of the terminal that is locatedwithin the container. The acid rings provide an extended interface andconsequently a tortuous path to inhibit or prevent electrolyte fromescaping from the battery container. Because the acid must follow anextended interface to escape this type of sealing, with a set ofconcentric acid rings, is often referred to as a labyrinth seal.

Because the battery terminals are cast or cold formed the radiallyprotruding acid rings are generally formed with either a rectangularcross sectional shape or a slight outward taper to facilitate removal ofthe battery terminals from the mold.

While battery terminals have a generally rectangular cross sectionalshape are used extensively other shaped acid rings have been used inorder to prevent the plastic container from shrinking away from theterminal and upsetting the interface between the battery part and thecontainer which could cause leakage of electrolyte. Generally, thesetype of acid rings provide lateral engagement between the acid ring andthe container.

For example, the 1971 United Kingdom patent specification GB 1236495discloses a battery terminal wherein two acid ring are bent toward eachother to provide a dovetail shaped gap that extends along the entirelength of the acid ring so that it enables the two adjacent acid ringsto form a dovetail joint with the battery container and thereby providelateral engagement between the acid ring and the container.

The 1971 United Kingdom patent specification GB 1,245,255 disclosesthree acid rings that have been deformed to create a dovetail shaped gapbetween adjacent acid rings with the dovetail gap extending along theentire length of the acid ring to form two dove tail joints with thecontainer and thereby provide lateral engagement between the acid ringand the container. In this embodiment the acid rings are compressedsufficiently to deform the acid rings so that the acid ring tapersinwardly along the entire length of the ring, that is from thecircumferential edge of the acid ring to the base of the acid ring.

The 1981 Japanese patent JP56159054 discloses a further embodimentwherein the battery terminal acid rings are deformed along the entirelength of the acid ring to form inclined projections on the acid ringsthat engage the cover to provide effective liquid tightness and therebyprovide lateral engagement between the acid ring and the container.

The 1993 Hofmann German patent DE 4127956 A1 discloses a batteryterminal wherein the ends of the acid rings have been rounded and thelower acid ring has been provided with a wedge shaped profile toincrease the sealing effect with a container and thereby provide lateralengagement between the acid ring and the container.

The 1994 Hofmann German patent DE 4241393 C1 discloses a batteryterminal wherein the ends of the acid rings have been rounded and a barbor undercut that forms a hook which is located on the back side of theacid ring. The “hook” on the back side of the deformed acid ring hooksinto the plastic container i.e. to lateral restrain the container toprevent the plastic battery container material from shrinking away fromthe battery terminal. In addition, a further embodiment is disclosedwherein adjacent acid rings are of the same thickness but are angledaway from each other in order to laterally restrain the container withrespect to the acid rings.

The 1992 Hofmann European patent 0 601 268 B1 discloses a batteryterminal wherein the ends of the acid rings either have a rounded end ora triangular shaped end with a barb or hook on the back side of the acidring. This “hook” on the back side of the deformed acid ring hooks theplastic to prevent the plastic battery container material from shrinkingaway from the battery terminal by laterally restraining the containerwith respect to the acid rings.

The 1992 Hofmann European patent application 0 601 268 A1 also disclosesthe battery terminal wherein the ends of the acid rings either have arounded end or a triangular shaped end with a barb or undercut or hookon the back sides of the acid ring. In addition, a further embodiment ofan acid ring is disclosed wherein two adjacent acid rings, which are ofthe same thickness, are angled away from each other to laterallyrestraining the container with respect to the acid rings by forming adovetail like joint.

The 1989 Hofmann German patent application DE 3942175A1 discloses amethod of forming a battery terminal with acid rings by cold rolling theterminal to form the circumferential acid rings.

U.S. Speigelberg U.S. Pat. No. 6,644,084 describes a process of formingan acid ring with a hook by first deforming the battery terminal from arectangular shaped acid ring to an arrowhead shaped acid ring. Thetransformation to the hook shape is obtained by rotating the batteryterminal relative to a cold forming roller to deform an acid ring with arectangular cross section into an acid ring having an undercut oroverhang. The cold rolling process involves substantial deformation ofthe acid ring on the cast battery part in order to produce the hook forengaging the battery container.

While the prior art provides acid rings with rectangular shapes that areeither bent or transformed into a different shape by cold rolling toform a lateral restraint between the battery container and the terminal.The lateral restraint is obtained by either forming a hook on the acidring or forming a dovetail or dovetail like engagement between thebattery container and the battery terminal.

In contrast to the prior art acid rings, where the shape of the acidring is substantially altered, in the present invention one can cast abattery part with the acid ring having a bifurcated end separated by acircumferential grove or an end with a single annular tapered lip. Thebifurcated end results in two outwardly extending annular lips on eachacid ring.

The annular lips on each acid ring can be flared away from each other toproduce a beveled surface or sealing bead along an annular outer portionof each of the annular lips which not only laterally restrains thecontainer with respect to the terminal but also forms an enhancedsealing region between the container and the acid ring. In addition thecircuitous path provided by the bifurcated acid rings can increase theresistance to electrolyte leakage by providing a more tortuous interfacebetween the acid rings and the container.

A further feature of the invention is the flaring of the lips can beobtained by applying a radial compressive force to the bifurcated endsof the acid ring. Since only the bifurcated ends of the acid ring areflared it substantially eliminates problems that can occur with priorart cold farming deformation of a pressure cast battery terminal. Thatis, an interface between a die cast portion of battery terminal and acold rolled portion of the battery terminal can lead to cracks or stressareas between the cast region and the cold formed region of the batterypart, which can be subject to electrolyte leakage therethrough. Byminimizing the interface one can minimize the opportunity for leakage.

Thus the flaring of the lips on the bifurcated acid ring of the presentinvention produces a back flare sealing region that extendscircumferential around the terminal which not only enhances sealing butalso restrains lateral engagement between the container and the acidrings and at the same time minimizing the occurrences of fractures orstress cracks in metal that has a portion of the original die cast shapealtered by cold rolled deformation.

The present invention provides a battery part that eliminates thesubstantial deformation or acid ring transformation necessary to eitherform an under cut or overhang on the acid ring or to deform an acid ringalong its entire length to form a dovetail engagement as shown in GB1236495; GB 1,245,255; JP 5619054 and EPO 06012681A1. In addition, thepresent invention further eliminates the need to mechanically deform theacid ring from a rectangular shape to an arrow head shaped acid ring orto an acid ring with a hook or an acid ring with a beveled surface thatextends along the entire length of the acid ring as shown inEP006012681B1 and DE 4241393.

Thus, by flaring the lip or lips on the circumferential end of the acidring one can form annular sealing regions, laterally restrain thecontainer with respect to the acid ring, and inhibit electrolyte fromescaping from the battery container with a more tortuous path. Not onlydoes the present invention inhibit escape of electrolyte by providing acircumferential sealing ring it also make it easier to flow the plasticaround the acid ring since the flared lip extends along only a portionof the acid ring. In addition, the present process minimizes stressproduced in the battery part when a substantial part of a die castbattery terminal is subsequently transformed to a substantiallydifferent shape by cold rolling since the lips on the end of the acidring can be flared instead of mechanically deformed into an entirelydifferent shape.

SUMMARY

Briefly, embodiments of the disclosure include a battery part such as abattery terminal with the battery part having an inclined sealing regionor sealing bead located on a lateral face of an acid ring with thesealing region increasing the resistance to leakage therepast as thecorresponding battery container shrinks. Another embodiment of thedisclosure includes a battery part with a bifurcated acid ring end and abeveled end face. The disclosure further includes a method of forming abattery terminal with an acid ring having a bifurcated end and a beveledface that permits one to use the battery terminal in an as is conditionor in a flared condition wherein the lips on the bifurcated end of theacid ring can be flared to form a beveled sealing region that functionslike an “O-ring” on the backside of the lip of the acid ring.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial cross sectional view of a battery terminal withbifurcated acid rings;

FIG. 2 is a partial cross sectional view of a chamber having a fluidizedparticles that impinge on a battery part therein;

FIG. 3 is a partial cross sectional view of the battery terminal of FIG.1 after being exposed to the fluidized media or particles as illustratedin FIG. 2;

FIG. 4 is a partial side view showing radial peening members for foldingover the ends of the bifurcated acid rings on a battery terminal;

FIG. 5 is a top view of three radial peening members located around theperiphery of a battery terminal with bifurcated acid rings;

FIG. 6 is a partial side view of a battery terminal having a set of acidrings with a valley or groove in the end face of the acid rings;

FIG. 7 is a top view of the battery terminal of FIG. 8 in a collet;

FIG. 7A is a sectional side view showing the beveled surfaces and thelateral surface on an acid ring with bifurcated lips;

FIG. 7B is an enlarged view of a portion of the acid rings to reveal thebeveled sealing surfaces on the acid ring; and

FIG. 8 is a partial side view of the battery terminal of FIG. 6 in acollet in an expanded condition;

FIG. 9 is a partial side of the battery terminal and collet when thecollet is partially contracted;

FIG. 10 is a partial side view of the battery terminal of FIG. 6 whenthe collet is in a contracted condition;

FIG. 11 is a partial side view of the battery terminal of FIG. 6 withthe acid rings having been deformed by the collet;

FIG. 12 is side view of an alternate embodiment wherein the acid ring isformed with a single lip on each acid ring;

FIG. 13 shows a tapered collet for deformed the battery terminal;

FIG. 14 shows a partial cross section view of a set of acid rings thathave been deformed by the collet of FIG. 13.

FIG. 15A is an enlarged view of a portion of a battery part illustratingvarious aspects of bifurcated acid rings configured in accordance withan embodiment of the present disclosure, and FIG. 15B is an enlargedcross-sectional view of the battery part of FIG. 15A after thebifurcated acid rings have been deformed in accordance with anembodiment of the disclosure.

FIG. 16A is a top view of an acid ring forming assembly configured inaccordance with an embodiment of the disclosure in an openconfiguration, and FIG. 16B is a cross-sectional side view of the openacid ring forming assembly taken along line 16B-16B in FIG. 16A.

FIG. 16C is a top view of the acid ring forming assembly of FIGS. 16Aand 16B in a closed configuration, and FIG. 16D is a cross-sectionalside view of the closed acid ring forming assembly taken along line16D-16D in FIG. 16C.

FIG. 17 is an enlarged cross-sectional side view taken from FIG. 16Dillustrating how protrusions on the acid ring forming assembly strikeacid rings on a battery part, in accordance with an embodiment of thedisclosure.

DETAILED DESCRIPTION

FIG. 1 shows a battery part 10 comprising a battery terminal having anupward extending lug 11 and a hollow base 12 having a central opening 13therein. Located around the exterior of battery terminal 10 is a set ofbifurcated annular acid rings 15, 16, 17, and 18 that have been formedby a die casting process. That is, a segmented mold (not shown) whichradially surrounds the sides of battery part 10 during the castingprocess has been pulled radially away from the battery part 10 torelease the battery part from the mold. Due to the configuration of thebattery part and the need to pull the side mold parts radially orlaterally away from the terminal the intermediate acid rings 15, 16 and17 are oftentimes each provided with a slight tapered. Each of the acidrings 15, 16 and 17 have been cast with an annular V shaped groovelocated in the end of each of the acid rings. The placement of thegroove in the end of acid ring generates a bifurcated circumferentialend to the acid ring with each of the bifurcated ends including radiallyextending annular lips which are located along the opposite lateralfaces of the acid rings 15, 16 and 17. Thus, a feature of the presentinvention is a battery terminal wherein the cast battery terminalscomprising a bifurcated acid ring 15 with a die cast upper annular lip15 a and a die cast lower annular lip 15 b. The end face of each of theacid rings are shown with an interior side surface or a bevel face 15 cand interior side surface or a bevel face 15 b that are joined at theroot of the acid ring to form a V shaped annular groove 15 e. Similarly,each of the bifurcated acid rings 16 and 17 have identical lips thatform an apex at the root of the lips and a V shaped annular groove onthe periphery of the annular acid ring.

In the embodiment shown in FIG. 1 the lower acid ring 18 is provide withan undercut 18 a which can be formed by an end mold (not shown) thatcoacts with the side molds. That is, the end mold can be used to formthe annular downward extending lip 18 b since the end mold can be movedaxially away from the end of the mold when the battery part is releasedfrom the mold.

Thus a feature of the present invention is the ability to cast a batteryterminal wherein after the casting process has been completed at leastone of the acid rings contains a lip or overhang 18 b that can be usedto seal the battery terminal to a battery container. Although anoverhang 18 can be cast with the present process of forming bifurcatedacid rings one may elect not to cast a terminal with an overhang andinstead use only the flared bifurcated ends of the acid rings tomaintain the sealing relationship between the container and theterminal.

FIG. 2 illustrates the battery terminal 10 located in a fluidized bedhaving particles 21 that impinge on the exterior surfaces or beveled endface of the acid rings 15, 16 and 17 of the battery terminal through theintroduction of fluid through lower openings 22. The impingement of theparticles, which are preferably harder than the battery part, provide atwo-fold effect. The first effect is that the particles impinging thebattery part can polish the exterior surface of the battery part. Thesecond effect is that it has been found that the impingement ofparticles on the beveled end surfaces of the acid ring can causes thelips of annular acid rings to fold over or flare out and create abeveled sealing region or sealing bead much like an O-ring on thelateral face of the acid rings. Thus, a feature of the present inventionis that one eliminates the need to form a “hook like” connection betweenthe battery terminal and the battery container or to deform the entireacid ring into a dovetail.

A reference to FIG. 3 shows how battery part 10 appears after beingsubjected to impingement from fluidized particles. To illustrate thefolding or flaring of the annular lip reference should be made to acidring 15 which shows lip 15 a curved upward and lip 15 b curved downward.That is, the impingement of particles on the bevel surface 15 c and 15 doccurs with sufficient force so that the annular lips 15 a and 15 b areflared outward to thereby creating a sealing region on the backsidethereof for sealing engaging and restraining a battery container withoutthe need for forming a hook on the battery part. Since the angledsurfaces 15 c and 15 d transmit a portion of the force in an axialdirection the lip can be flared or folded outward through the radialimpingement of particles on the angled surfaces 15 c and 15 d. As eachof the bifurcated annular rings 16 and 17 have identical annular lipseach of the bifurcated annular rings 16 and 17 produce a sealing regionon the lateral face of the acid sealing rings for sealing engagementbetween container and terminal while laterally restraining a batterycontainer with respect to the terminals without the use of a hook whichcould trap air therein during the formation of the container andconsequently produce regions with enhanced risk of electrolyte leakage.However, if the lips are flared outward slightly to produce a sealingbead the trapped air can flow smoothly outward during the moldingprocess and one need not be concerned with air being trapped in a “hook”on the backside of the acid ring.

While the battery part has been placed in a fluidized bed so thatparticles can be directed against the beveled side surface of the acidrings other methods of impinging particles against the surface such asin a tumbler where the battery part and harder media are allowed tocontact the battery part as the media and the battery part are tumbledabout can be used to deform the annular lips on the cast battery part.That is, in another flaring process the use of a deformable materialsuch as a lead or lead alloy allows one can flare or bend the lips onthe acid rings to the desired shape through contact of an article orparticles with the angled side surfaces on the axially spacedcircumferential acid rings.

FIG. 4 shows a side elevation view of a different system and method forfolding or flaring the annular lips into a container engaging protrusionor sealing region on the terminal. In the embodiment shown the batteryterminal 30 contains annular acid rings 31 with a V-shaped groove in theend face. A set of radially displaceable peening or flaring members 35and 36 are positioned proximate the acid rings. In the embodiment shownthe peening member 35 includes curved protrusions 35 a, 35 b and 35 cwhich are located in the same plane as acid rings 31, 32 and 32.Similarly, peening member 36 includes peening protrusions 36 a, 36 b and36 c that are located in the same plane as acid rings 31, 32 and 33. Theradial inward displacement of member 35 and 36 brings the peeningprotrusions into engagement with the V-shaped grooves in each of theacid rings which causes the annular lips of the acid rings to be foldedoutward or flared outward as illustrated in FIG. 3 to thereby form asealing region or a rigid sealing ring on the backside of the acid ring.

FIG. 5 shows a bottom view of how a multiple part radial peening membercan peen or compress the bifurcated acid rings so each of the acid ringshave a lip or protrusion for engaging a container. In the embodimentshown, a first arcuate shaped peening member 42 which is radiallypositionable through a hydraulic cylinder 42 a includes a peeningsurface 42 b that is an alignment with the acid ring 40 a. Similarly,positioned around terminal 40 are peening members 41 and 43 thatcooperate to form a closed annular peening member that engages and foldsor flares the lips on the annular acid ring backward into the hooking orcontainer engaging protrusion illustrated in FIG. 3 by radial inwarddisplacement of the peening members into the angled side surfaces of theannular lips on the acid ring. Thus FIG. 5 illustrates one method offorming sealing regions on the bifurcated acid rings by directing amember into the V-shaped grooves in the end faces of the bifurcated acidrings.

While the invention has been described in regard to die casting thebattery terminal could also be formed from other casting methods orthrough cold forming.

FIG. 6 shows a preferred embodiment of the invention comprising abattery part 50 such as a battery terminal with a set of spacedbifurcated acid rings 51, 52 and 53. The bifurcated acid rings extendaround the peripheral region of the battery part and can have any numberof shapes including circular, hexagonal or the like. Although one acidring can be sufficient for engagement with a battery container thebattery part 50 generally includes at least three lateral spaced acidrings that extend radially outward from the base 55 of battery part 50.

Battery part 50 includes a connector lug 56 having an exterior surface56 a for forming an electrical connection to an external device. In theembodiment shown the battery terminal 50 includes a hollow centralopening 57 to permit one to pour molten metal therein to form anelectrical connection to an internal battery components such as abattery plate or the like.

FIG. 7A shows an isolated view of a portion of bifurcated acid ring 51to reveal in detail the lip 60 with a first face or lateral face 60 a onone side and a second face, namely a beveled end face 60 d on the otherside of lip 60 with the lateral face 60 a and the beveled end face 60 dforming an included angle of less than 90 degrees therebetween.Similarly, a second lip 61 includes a first face or lateral face 61 a onone side and a second face, namely, a beveled end face 61 d on theopposite side with the lateral face 61 a and the beveled end face 61 dforming an included angle of less than 90 degrees therebetween. Inaddition, the beveled end face 60 d intersects beveled end face 61 d atan apex 61 e to form a valley or V-shaped groove between the lip 60 onone face of the acid ring and the lip 61 on the opposite face of theacid ring 51.

FIG. 7B shows acid rings 51, 52 and 52 in a partial view in FIG. 7A withthe lips in a flared condition to form a lateral sealing region orsealing bead on the lateral faces of the acid rings to thereby enhancethe sealing of a battery container to the terminal. The beveled surface60 d of the first lip 60 and the beveled surface 61 d of second lip 61are located at approximately a ninety degree angle to each otheralthough the angle can vary depending on the selection of the angle ofthe beveled surface for each lip. In the embodiments shown the lips 60and 61 which were previously in an unflared condition (FIG. 7A) and anapex 60 f and 61 have been transformed to a flared condition. The lip 60has a an extended flat surface 60 c and lip 61 has an extended flatsurface 61 c.

While FIG. 7A illustrates the acid ring in the unflared condition, FIG.7B shows the acid rings in a flared condition. In the flared conditionthe lips on the bifurcated acid rings have been flared laterally to forma sealing region or sealing bead along the lateral faces of the acidrings.

FIG. 7A shows acid ring 51 in the as cast condition revealing lip 60 andlip 61 in an a straight or unflared condition. In the embodiments shownbifurcated acid ring 51 has a first lateral face 60 a and a secondlateral face 61 located in a substantially parallel relation ship toeach other.

FIG. 7B shows bifurcated acid ring 51 in the flared condition. In theflared condition the bifurcated acid ring 51 includes a firstcircumferential end face 60 c and a second circumferential end face 61 cseparated by a first circumferential beveled end face 60 d and a secondcircumferential beveled end face 61 d. In the flared condition a firstcircumferential sealing region or sealing bead 60 b extends around theouter portion of lateral face 60 a and a second circumferential sealingregion or sealing bead 61 b extends around the outer portion of lateralsurface 61 a. As can be seen in FIG. 7B the lip 60 c located on the acidring 51 and the lip 61 located on acid ring 51 have been flared upwardto form the respective sealing regions 60 b and 61 b. The sealingregions have a lateral length denoted by x and extend partially alongthe lateral faces of the acid ring. Each of the sealing regions extendcircumferentially around the battery terminal to provide a 360 degreesealing barrier between the container and the battery container.

In order to appreciate the transformation of the battery terminal with abifurcated acid ring into a battery terminal with cantilevered sealingregions reference should be made to FIGS. 7 and 8 which shows a collet81 in top view. FIG. 8 shows a section view the battery terminal 50positioned between a set of cantilever mounted splines 71, 72, 73, 74and 75 on the collet 81. FIGS. 7-10 illustrate a battery terminal placedin collet 81 and the collet collapsed to radially compress the lips onthe acid ring to form a sealing bead on the lateral surface of the bead.

FIG. 7 shows a top view of the battery terminal 50 centrally positionedbetween the splines 71-77 that are cantilevered held in a base member(not shown). A compression collar 80 extends around each of the splinesso that when the collar is forced upward the splines are broughtradially inward to flare the lips on acid rings 51, 52 and 53.

FIG. 8 shows a section view of collet 81 surrounding battery terminal 50with the splines 71, 72, 73 and 74 in a spaced condition about thebifurcated acid rings 51, 52 and 53. If desired a mandrel (not shown)can be inserted into battery terminal 50 to hold the battery terminal inposition.

FIG. 9 shows the initial step in the formation of the sealing regions onthe bifurcated acid rings 51, 52 and 53. In this condition the splines71-75 have been brought into contact with the lips on the bifurcatedacid rings 51, 52 and 53 while the acid rings are free to self center inthe collet.

FIG. 10 shows the compression step wherein the splines 71-75 have beensqueezed radially inward to flare the lips on acid rings 51, 52 and 53sufficient to form a sealing bead on the lateral surface of each of thelips on the acid rings but insufficient to form the lips into a hook.That is the deformation, which is shown in greater detail in FIG. 7B,produces an inclined sealing region or sealing bead that extends along aportion of the backside of the flared lip of the acid ring. In theembodiment shown the radius of curvature of the collet and the radius ofcurvature of the acid rings are substantially equal so as to produce auniform flaring of the lip.

FIG. 11 shows terminal 50 after compression by collet 81. As can be seenin FIG. 11 each of the lips on the acid rings 51, 52 and 53 have beenflared to create the sealing regions illustrated in FIG. 7B. In contrastto the deformation of the rectangular shaped acid rings as shown in theprior art the compression of the bifurcated acid ring involves only aslight deflecting of the lips to create the sealing bead thus minimizingthe stress lines that can be caused by the junction between a coldforming portion on a die cast battery terminal.

FIG. 12 is side view of an alternate embodiment of a battery part 80wherein the acid rings 81, 82 and 83 are formed with a single lip oneach acid ring. That is acid ring 81 has a lateral surface 81 a and abeveled surface 81 b that form an angle of less than 90 degrees andpreferably 45 degrees of less so as form a lip that can be flared upwardsufficiently to form a sealing bead on the lateral surface 81. In thisembodiment the radial compression with the collet will form a topbeveled sealing region on each lip to laterally restrain the containerand simultaneously form an effective seal that inhibits the loss ofelectrolyte therepast.

FIG. 13 shows a collet 90 having a base with cantilevered sections 90 b,90 a and 90 c. Located on an inside face of the cantilevered colletsections are a set of annular ridges 91, 91 a and 91 b. An annular ridge91 is adjacent a recess 92 as are the other ridges 91 a and 91 b alsoproximate a recess. In the embodiment shown the collet makes an angle θwith a line parallel to a central axis of the collet. The purpose of theangle in the collet face is to allow one to form acid rings on a batteryterminal having a tapered base. The spacing of each of the ridges oncollet 90 are such that the ridges align with the V shaped recess in thebifurcated acid ring as illustrated in FIG. 4.

FIG. 14 shows a partial sectional view of a battery terminal 95 whereinthe collet 90 of FIG. 13 has been used to compress the bifurcated acidrings 96, 97 and 98. Each of the bifurcated acid rings have beenradially compressed to deform the acid rings so as to produce a teardrop shaped recess 99 between adjacent acid rings wherein the lower partof the recess has a width x₂ that is larger than the entry region widthx₁ to the recess to thereby form a retaining pocket to received themolten material used to form the container around the battery terminal.As shown in FIG. 14 the bifurcated acid ring 96 has an upper curved face96 c and a lower curved face 96 d on opposite side of the undeformedportion 96 f of the bifurcated acid ring 96 as a result of the acid ringhaving been deformed radially inward by collet 90. When each of the acidrings are subject to a squeezing by collet 90 the compression results ina smoothly curved surface 96 a on the top side of acid ring 96 and asmoothly curved surface 97 b on the bottom side of acid ring 97 thatcoact to form a tear drop shaped recess 99 for locking a batterycontainer thereto. Similarly, the acid ring 98 has been deformed and thelower curved surface 97 b coacts with upper curved surface 96 a to forma further tear drop shaped pocket therebetween that can trap the moltenplastic therein and assist in forming a leakproof seal. As can be seenin FIG. 14 each of the acid rings converges from an exterior portion ofthe acid ring to an internal portion of the acid ring. For example,surface 96 c and 96 b of acid ring 96 smoothly curve from the outer mostportion or entry region to the recess to the inner most point or thebottom of the recess.

While the invention has been shown with circular battery terminals theinvention can also be used with battery terminals that are other thancircular such as oblong. In those instance a multiple part die asopposed to a collet can be used to deform the bifurcated acid rings intoa condition where a retaining pocket is formed between.

FIG. 15A is an enlarged side view of a portion of a battery part, suchas a battery terminal 1550, illustrating a plurality of acid rings 1551(identified individually as a first acid ring 1551 a and a second acidring 1551 b) configured in accordance with an embodiment of thedisclosure. FIG. 15B is an enlarged cross-sectional view of the batteryterminal 1550 after the acid rings 1551 have been deformed in accordancewith an embodiment of the disclosure. Many features of the batteryterminal 1550 are at least generally similar in structure and functionto corresponding features of the battery parts 10, 30, 50, 80, and/or 95described in detail above.

Referring first to FIG. 15A, in the illustrated embodiment each of theacid rings 1551 is a bifurcated acid ring. The first acid ring 1551 a,for example, includes a first annular lip 1560 a spaced apart from asecond annular lip 1560 b by a V-shaped groove 1562 therebetween. Thefirst lip 1560 a includes a first lateral surface 1566 a and a first endface or beveled surface 1564 a. In the illustrated embodiment, the firstbeveled surface 1564 a forms an acute angle with respect to the firstlateral surface 1566 a. The second lip 1560 b similarly includes asecond lateral surface 1566 b and a second beveled surface 1564 b. Theopposing beveled surfaces 1564 define the V-shaped groove 1562.

The second lateral surface 1566 b of the first acid ring 1551 a isspaced apart from a third lateral surface 1566 c of the second acid ring1551 b by a distance S₁ that defines a gap 1563 therebetween. In theillustrated embodiment, the distance S₁ can be from about 0.04 inch toabout 0.2 inch, or about 0.089 inch. Moreover, in the illustratedembodiment the second lateral surface 1566 b can extend outwardly fromthe battery terminal 1550 at a slight angle relative to the thirdlateral surface 1566 c so that the opposing lateral surfaces 1566 b and1566 c define a slightly diverging angle A₁ (e.g., a “draft” angle)therebetween. For example, in the illustrated embodiment the angle A₁can be from about zero degrees to about six degrees, or about fourdegrees. The angle A₁ can facilitate removal of the die from the batteryterminal 1550 (or vice verse) during a casting process. As discussed ingreater detail below, after the acid rings 1551 have been formed asshown in FIG. 15A, the lips 1560 (e.g., the first lip 1560 a and thesecond lip 1560 b) can be flared outwardly from each other or otherwisedeformed to produce an undercut region 1599 (FIG. 15B) between adjacentacid rings 1551.

FIG. 16A is a top view of an acid ring forming assembly 1610 configuredin accordance with an embodiment of the disclosure for compressing,folding, flaring, peening and/or otherwise forming acid rings (e.g., theacid rings 1551) and/or other features (e.g., other sealing features) onbattery terminals (e.g., the battery terminal 1550) and/or other batteryparts. FIG. 16B is a cross-sectional side view of the forming assembly1610 taken along line 16B-16B in FIG. 16A. Referring to FIGS. 16A and16B together, the forming assembly 1610 includes a first-forming member1612 a and a cooperating second-forming member 1612 b movably coupled toa tool base 1614. In the illustrated embodiment, each of the formingmembers 1612 is configured to slide back and forth along a longitudinalaxis 1620 in guide tracks 1616 (identified individually as a first guidetrack 1616 a and a second guide track 1616 b) formed in adjacentsidewalls 1618 of the base 1614.

In another aspect of this embodiment, the forming assembly 1610 furtherincludes a part support 1660 extending upwardly from a central portionof the base 1614. In the illustrated embodiment, the part support 1660includes a peg having a distal end portion 1662 configured to removablyreceive the battery terminal 1550. More particularly, the distal endportion 1662 includes a cylindrical shaft portion or projection thatextends through a central opening in the battery terminal 1550 to firmlysupport the battery terminal 1550 during the acid ring forming processdescribed in more detail below. In the illustrated embodiment, thevarious components of the forming assembly 1610 described above (e.g.,the forming members 1612, the base 1614, and the part support 1660) canbe machined, cast, or otherwise formed from steel, aluminum, iron,and/or another suitable materials (e.g., other non-metallic materialsincluding ceramics, composites, etc.) known in the art for havingsufficient strength, hardness, and/or other desirable characteristics.

Each of the forming members 1612 includes a corresponding formingportion 1630 (identified individually as a first-forming portion 1630 aand a second-forming portion 1630 b) having one or more protrusions 1635(identified individually as protrusion 1635 a-d) extending laterallyalong an interior surface thereof in lateral and vertical alignment withthe corresponding acid rings 1551 on the battery terminal 1550. In theillustrated embodiment, each of the forming portions 1630 defines asemicircular recess configured to receive a portion (e.g., a half) ofthe battery terminal 1550 when the forming members 1612 move inwardlyfrom the open position shown in FIGS. 16A and 16B to the closed positiondiscussed below with reference to FIGS. 16C and 16D.

A first driver 1640 a can be operably coupled to the first-formingmember 1612 a and a second driver 1640 b can be operably coupled to thesecond-forming member 1612 b. In the illustrated embodiment, the drivers1640 can include hydraulic devices (e.g., pressurized hydrauliccylinders) that can be activated to drive the respective forming member1612 toward the closed position to compress the battery terminal 1550between the opposing forming portions 1630. In other embodiments,pneumatic, electro-mechanical, and/or manual devices can be used todrive the forming members 1612 against the battery terminal 1550 andthen retract the forming members 1612 away from the battery terminal1550. It is contemplated that in certain embodiments only one of theforming members 1612 (and possibly the part support 1660) may be movableduring the forming process, while the other forming member 1612 remainsstationary or at least approximately stationary.

FIGS. 16A and 16B illustrate the forming assembly in an open positionwith the battery terminal 1550 temporarily placed on the part support1660 for deforming the acid rings 1551. To form the acid rings 1551, thedrivers 1640 simultaneously drive the opposing forming members 1612toward each other until the protrusions 1635 on the forming portions1630 impact the acid rings 1551 as shown in FIGS. 16C and 16D. Afterimpact, the drivers 1640 can retract the forming members 1612 so thatthe formed battery terminal 1550 can be removed from the part support1660 and replaced with another terminal ready for forming.Alternatively, the battery terminal 1550 can be struck multiple times toform the acid rings 1551 to the desired shape in stages.

FIG. 17 is an enlarged cross-sectional side view taken from FIG. 16Dillustrating how the protrusions 1635 on the forming member 1612 bdeform the acid rings 1551 in accordance with an embodiment of thedisclosure. As this view illustrates, each of the protrusions 1635 ofthe illustrated embodiment is at least approximately wedge or V-shapedand includes a vertex or apex 1736 with adjacent side surfaces 1738(identified individually as a first side surface 1738 a and a secondside surface 1738 b). Accordingly, when the forming portion 1630 b isdriven against the base of the battery terminal 1550, the apex 1736 ofthe protrusion 1635 c, for example, drives into the V-shaped groove 1562between the first lip 1560 a and the second lip 1560 b of the acid ring1551 a. More particularly, the first side surface 1738 a of theprotrusion 1635 c presses against the first beveled end face 1564 a ofthe first lip 1560 a, and the second side surface 1738 b presses againstthe second beveled end face 1564 b of the second lip 1560 b. As theprotrusion 1635 c presses inwardly, it flares the lips 1560 a, boutwardly and away from each other as shown in FIG. 17. After forming,the forming members 1612 are pulled back from the battery terminal 1550,and the battery terminal 1550 is lifted off of the part support 1660.

Returning now to FIG. 15B, this Figure illustrates the acid rings 1551after crimping or flaring using the systems and methods described above.As this view illustrates, the gap 1563 between the adjacent acid rings1551 a and 1551 b has now closed to a distance S₂ which is less than theoriginal distance S₁ (FIG. 15A). For example, in the illustratedembodiment the distance S₂ can be from about 0.02 inch to about 0.08inch, or about 0.052 inch. Flaring the acid ring lips 1560 outwardly inthis manner causes the opposing lateral surfaces 1566 b and 1566 c todefine a converging angle A₂ therebetween. In the illustratedembodiment, the angle A₂ can be from about 15 degrees to about 35degrees, or about 25.6 degrees. Moreover, the outward flare of the acidring lips 1560 creates an undercut U beneath each lip 1560 of from about0.008 inch to about 0.02 inch, or about 0.013 inch. The undercut acidring lips 1560 coact to form an undercut region 1599 (e.g., an inwardlyopening region) that is at least generally similar in structure andfunction to the teardrop shaped recess 99 described above with referenceto FIG. 14. More specifically, the undercut region 1599 creates a pocketbetween the adjacent acid rings 1551 that can trap molten batterycontainer plastic therein and assist in forming a leakproof seal thatlocks the battery container thereto.

From the foregoing, it will be appreciated that specific embodiments ofthe invention have been described herein for purposes of illustration,but that various modifications may be made without deviating from thespirit and scope of the various embodiments of the invention. Further,while various advantages associated with certain embodiments of theinvention have been described above in the context of those embodiments,other embodiments may also exhibit such advantages, and not allembodiments need necessarily exhibit such advantages to fall within thescope of the invention. Accordingly, the invention is not limited,except as by the appended claims.

1-6. (canceled)
 7. A battery terminal manufacturing system comprising: atool assembly including: a base; a first forming member movably coupledto the base and having a first recess with at least a first protrusionextending from an interior surface thereof; a second forming membermovably coupled to the base and having a second recess with at least asecond protrusion extending from an interior surface thereof; and a partsupport fixedly attached to the base and positioned between the firstand second forming members; and an unfinished battery terminal removablypositioned on the part support, wherein the battery terminal includes atleast one annular ring protruding from an exterior surface thereof,wherein the first and second forming members move toward each otheralong an axis to receive the battery terminal in the first and secondrecesses, whereby the first and second protrusions cooperate to compressand deform at least a portion of the annular ring.
 8. The manufacturingsystem of claim 7 wherein the at least one annular ring of theunfinished battery terminal is a bifurcated acid ring having a first lipportion spaced apart from a second lip portion, and wherein the firstand second protrusions are driven against the unfinished batteryterminal between the first and second lip portions to flare the lipportions away from each other.
 9. The manufacturing system of claim 7wherein: the first forming member further includes a third protrusionextending from the interior surface of the first recess, and the secondforming member further includes a fourth protrusion extending from theinterior surface of the second recess; the unfinished battery terminalfurther includes at least a second annular ring offset from the firstannular ring, wherein the first annular ring is a first bifurcated acidring having a first lip portion spaced apart from a second lip portion,wherein the second annular ring is a second bifurcated acid ring havinga third lip portion spaced apart from a fourth lip portion; the firstand second protrusions are driven against the first and second lipportions to flare the first and second lip portions away from eachother; and the third and fourth protrusions are driven against the thirdand fourth lip portions to flare the third and fourth lip portions awayfrom each other.
 10. The manufacturing system of claim 7, furthercomprising means for moving the first and second forming members towardeach other along the axis to drive the first and second protrusionsagainst at least a portion of the annular ring.
 11. A battery terminalmanufacturing system comprising: a base portion; a part support attachedto the base portion, wherein the part support is configured to receivean unfinished battery terminal having at least one annular ringprotruding from an exterior surface thereof; a first forming membermovably coupled to the base portion and having a first forming portiondefining a first recess with at least a first protrusion extending froman interior surface thereof; and a second forming member movably coupledto the base portion and having a second forming portion defining asecond recess with at least a second protrusion extending from aninterior surface thereof, wherein the first and second forming portionsare configured to move toward the part support and compress at least aportion of the annular ring between the first and second protrusions.12. The manufacturing system of claim 11 wherein the at least oneannular ring includes a lip, and wherein the first and second formingportions are further configured to compress the at least one annularring to form an undercut region between the first lip and the exteriorsurface of the at least one annular ring.
 13. The manufacturing systemof claim 11 wherein the at least one annular ring includes a first lipand a second lip, and wherein the first and second forming portions arefurther configured to compress the at least one annular ring to flarethe first and second lips away from each other.
 14. The manufacturingsystem of claim 11 wherein the at least one annular ring is a firstannular ring having a first lip, wherein the unfinished battery terminalincludes a second annular ring having a second lip, and wherein thefirst and second forming portions are further configured to compress thefirst and second annular rings to flare the first and second lips towardeach other.
 15. The manufacturing system of claim 14 wherein the firstand second lips have corresponding first and second opposing lateralsurfaces, and wherein the first and second forming portions are furtherconfigured to flare the first and second lips toward each other suchthat an angle between the first and second opposing lateral surfaces is35 degrees or less.
 16. The manufacturing system of claim 11, furthercomprising at least one guide track on the base portion, wherein thefirst and second forming members are slidably coupled to the baseportion and configured to move relative to the base portion in the atleast one guide track.
 17. The manufacturing system of claim 11, furthercomprising means for moving the first forming member toward the partsupport to drive the first and second protrusions against at least aportion of the annular ring.
 18. The manufacturing system of claim 11wherein the first and second forming portions are configured to movetoward the part support along an axis.
 19. A battery part manufacturingsystem comprising: a first forming portion including a first recesshaving an interior surface with a first protrusion extending therefrom;a second forming portion including a second recess having an interiorsurface with a second protrusion extending therefrom; a battery partholder positioned between the first and second forming portions, whereinthe battery part holder is configured to receive an unfinished batterypart having at least one annular ring protruding from an exteriorsurface thereof; and a first driver operably coupled to the firstforming portion, wherein the first driver is configured to drive thefirst forming portion toward the battery part holder and the secondforming portion such that the first and second protrusions impact and atleast partially deform a portion of the at least one annular ring. 20.The manufacturing system of claim 19 wherein the at least one annularring includes a first lip and a second lip, and wherein the first driveris further configured to drive the first forming portion toward thebattery part holder and the second forming portion such that the firstand second protrusions impact the at least one annular ring and flarethe first lip away from the second lip.
 21. The manufacturing system ofclaim 19 wherein the at least one annular ring includes a first lip anda second lip, and wherein the first driver is further configured todrive the first forming portion toward the battery part holder and thesecond forming portion such that the first and second protrusions impactthe at least one annular ring and form a V-shaped groove between thefirst and second lips
 22. The manufacturing system of claim 19 whereinthe at least one annular ring is a first annular ring having a firstlip, wherein the unfinished battery part further includes a secondannular ring having a second lip, and wherein the first driver isfurther configured to drive the first forming portion toward the batterypart holder and the second forming portion such that the first andsecond protrusions impact the first and second annular rings to flarethe first lip toward the second lip.
 23. The manufacturing system ofclaim 19 wherein the first and second drivers are further configured tosimultaneously drive the first and second forming portions toward thebattery part holder.
 23. The battery part manufacturing system of claim19, further comprising a second driver operably coupled to the secondforming portion, wherein the second driver is configured to drive thesecond forming portion toward the battery part holder.
 24. Themanufacturing system of claim 23 wherein the first driver is configuredto drive the first forming portion along an axis toward the battery partholder, and wherein the second driver is configured to drive the secondforming portion along the axis toward the battery part holder.